Cup product for use in brassier and brassier using the cup product

ABSTRACT

A cup product for use in a brassier and a brassier or like product using the cup product are disclosed. The cup product has a cup for covering a breast, a scallop portion provided at a peripheral edge of the cup, and an ornamental lace portion provided over a surface of the cup. The scallop portion and the ornamental lace portion are provided as one continuous lace fabric, and this lace fabric is formed into a three-dimensional shape by means of molding with the scallop portion being placed at an end of the three-dimensional shape.

[0001] The present invention relates to a cup product for use in abrassier having a scallop portion provided at an edge of a cup forcovering a breast and an ornamental lace portion provided on a surfaceof the cup. The invention relates also to a brassier using such product.

BACKGROUND OF THE INVENTION

[0002] A cup product C for use in such a brassier, as shown in FIG. 8,often includes a lace 61 on its surface. In recent years, there ispreference among consumers for a cup product C having a so-calledscallop S at an upper edge thereof which comprises a continuouswave-like ornamental portion.

[0003] Referring to a specific example of such component, as shown in anexploded view in FIG. 7, the cup product includes a three-dimensionallyformed urethane cup Ca, pre-determined cloths 62, 63 attachedrespectively to the front and back sides of the cup Ca, and a scalloplace cloth S attached to the upper edge of the cup product C as acontinuous wave-like ornamental portion.

[0004] For manufacturing such cup product C as above, first, thethree-dimensionally molded cup Ca is prepared and also a wide lacematerial prepared as a planar knitted fabric is three-dimensionallyformed (specifically, molded) into a shape required by the end product.Thereafter, as illustrated in FIG. 9 (portions to be three-dimensionallyformed are denoted by mark M and cutting lines are denoted by brokenlines), the lace material is formed into the predetermined shape toobtain the cloth 62 as the front-side lace member. Similarly, theback-side cloth 63 is formed three-dimensionally.

[0005] Then, according to the convention, for providing the scallop lacecloth S, there is separately prepared a scallop lace material Sa, asillustrated in FIG. 7.

[0006] In summary, for manufacturing a brassier by the above-describedconventional method, there are prepared, as the major componentsthereof, the urethane cup Ca, the molded lace cloth 62, the moldedback-side cloth 63 as well as the scallop lace material Sa. Then, thesemembers are sewn together to form the cup product C having the scallop Sat the predetermined edge thereof.

[0007] In manufacturing the lace cloth 62 molded in the manner describedabove, as a base material, there is prepared a wide lace material havinga relatively large width. Then, the predetermined portions M of thismaterial are molded.

[0008] On the other hand, the brassier includes a pair of cups forcovering breasts, a central connecting portion for interconnecting thecups at the center therebetween and other members such as shoulderstraps and a back strap. Accordingly, in order to obtain a brassier, itis necessary to prepare at least one pair of right and left cups.

[0009] In recent years, there has been proposed a new brassierconstruction adapted for drawing the user's breasts closer to each othertoward the center of chest when the brassier is worn by the user, inorder to e.g. provide improved silhouette of the breasts (to increasethe “depth” between the breasts when supported by the brassier).

[0010] Conventionally, for manufacturing a cup product for use in such“center-drawing” type brassier, a mold having a spherical end isemployed to obtain a pair of semi-spherical molded members (the shapeshown in FIG. 10(b)) an then these members are sewn together withoffsetting the maximum bulging portions of the members toward the centertherebetween (represented by broken lines in FIG. 10(e)), thereby toobtain the major components of the brassier to be fitted over the pairof user's breasts.

[0011] Another conventional method involves appropriatethree-dimensional cutting and three-dimensional sewing of thesemi-spherical cup member to obtain a brassier cup having a desiredshape.

[0012] The conventional methods described above have two problemsconcerning the appearance as follows.

[0013] 1. Problem concerning the connecting portion between theornamental lace portion and the scallop portion:

[0014] For manufacturing the cup product C such as shown in FIG. 8, itis necessary to prepare an urethane cup Ca, a front-side lace cloth 62,a backside cloth 63 and a scallop lace cloth Sa and then to sew thesemembers together. Hence, there is the problem of appearance due to thepresence of numerous sewn portions T as shown in FIG. 8, Accordingly,this method is very troublesome. Moreover, as each of these sewnportions T is sewn together with a tape t applied thereto, the sewnportion gives a rough surface feel to the user.

[0015] 2. Problem concerning the formation of desired worn silhouette

[0016] On the other hand, referring to the worn silhouette, theabove-described conventional method for manufacturing the brassier usingthe semi-spherical molded cups with their maximum bulging portions (i.e.the apices of the semi-spheres) offset closer to each other (see FIG.10(e)) requires high precision in the cutting and sewing steps. And,with this method, it is often difficult to obtain a desired uniformsilhouette. Hence, in these respects, there exists room for improvementin this conventional method.

[0017] The other conventional method involving three-dimensional cuttingand three-dimensional sewing is troublesome, thus inviting costincrease.

[0018] In view of the above-described state of the art, the primaryobject of the present invention is to provide a cup product for use in abrassier and a brassier using such cup product, which use a lace fabrichaving a scallop portion, yet can provide improved appearance andsilhouette without inviting cost increase.

SUMMARY OF THE INVENTION

[0019] For accomplishing the above-described object, according to claim1 of the present invention, there is provided a cup product for use in abrassier, the cup having a cup for covering a breast, a scallop portionprovided at a peripheral edge of the cup, and an ornamental lace portionprovided over a surface of the cup;

[0020] wherein the scallop portion and the ornamental lace portioncomprise one continuous lace fabric, and this lace fabric is formed intoa three-dimensional shape by means of molding with the scallop portionbeing placed at an end of the three-dimensional shape.

[0021] According to the above-described cup product, the ornamental laceportion provided on the surface of the cup and the scallop portioncomprise one continuous or seamless knitted lace fabric. Therefore,there is no need to provide a seam, a tape, etc. between the ornamentallace portion and the scallop portion. As a result, it becomes possibleto obtain a brassier with much improved appearance.

[0022] Moreover, with the reduced number of steps involved in themethod, the method allows production at lower costs.

[0023] In the construction described above, according to claim 2, thecontinuous knitted lace fabric is formed by means of the molding overthe peripheral edge of the cup around a maximum bulging center thereof.

[0024] In a finished brassier cup product, the ornamental feature ismost important at the peripheral edge of the cup bridging between thescallop portion and the ornamental lace portion. In addition to this,the ornamental feature at the maximum bulging center of the cup and theperiphery of this center is also important. In particular, in the areaabove the maximum bulging center of the cup, the ornamental lace portionis usually provided. And, at this area, it is desired that theornamental pattern be formed continuous.

[0025] For instance, if a three-dimensional cutting or sewing is donefrom the peripheral edge of the cup toward the maximum bulging centerthereof, this will provide discontinuity in the ornamental pattern atthis portion, resulting in deteriorated appearance.

[0026] On the other hand, if the continuity of the knitted lace fabricis maintained from the maximum bulging cup center to the entire cupperipheral edge (i.e. 360 degrees around the peripheral edge) asdescribed above, the integrity of the ornamental pattern is maintained,and also the three-dimensional shape of the cup is well reserved. As aresult, it becomes possible to obtain a brassier cup product having sillhigher aesthetic and commercial value.

[0027] Further, according to claim 3, the knitted lace fabric is anelastic lace fabric having elasticity in either a weft direction or warpdirection of the fabric or elasticity in both these directions.

[0028] Conventionally, the lace fabric to be used in a brassier cupproduct is a rigid or non-elastic knitted fabric. However, if the fabricis to be formed into a relatively complicated three-dimensional shape asis the case with the present invention, with use of such elastic fabrichaving elasticity in the weft and/or warp directions thereof, thethree-dimensional forming step may be carried out smoothly withoutinviting breakage in the lace fabric. As a result, the cup may bemanufactured without such troubles as looseness or breakage.

[0029] For the purpose of providing improved silhouette, according toclaim 4, a proximal portion of the cup close to the center of thebrassier corresponding to the “valley” between the breasts has a greaterbulging curvature than a distal portion of the cup distant from thecenter of the brassier.

[0030] With the above, the bulging curvature of the proximal cup portionis differentiated from that of the distal cup portion, with the formerbeing greater than the latter. Accordingly, this cup has a greaterbulging volume at the proximal portion adjacent the center of thebrassier, so that the breasts supported in these cups will be drawncloser to each other toward the center therebetween.

[0031] More preferably, as set forth in claim 5, the maximum bulgingcenter of the cup is located at the proximal cup portion adjacent thecenter of the brassier corresponding to the valley between the breasts.

[0032] Accordingly, this cup allows the positions of nipples or theentire breasts to be drawn closer to each other, so as to provide thedesired effect.

[0033] In the above construction, more preferably, the cup is providedas a deformed cup having a proximal portion close to the center of thebrassier corresponding to the “valley” between the breasts which portionhas a greater bulging curvature than a distal portion of the cup distantfrom the center of the brassier, the deformed cup having a maximumbulging center at the proximal cup portion thereof close to the centerof the brassier corresponding to the valley between the breasts.

[0034] Further and other objects and advantages of the invention willbecome apparent upon reading the following detailed description ofpreferred embodiments thereof with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0035]FIG. 1 is a schematic illustration showing a structure of aknitted lace fabric,

[0036]FIG. 2 is an illustration of a three-dimensional forming device,

[0037]FIG. 3 is an illustration of a three-dimensional lace materialjoined with a polyurethane cup,

[0038]FIG. 4 is a view showing a three-dimensional lace product,

[0039]FIG. 5 is an illustration showing a further embodiment of the lacefabric,

[0040]FIG. 6 is an illustration showing a still further embodiment ofthe present invention,

[0041]FIG. 7 is an exploded view showing principal components employedby the conventional method,

[0042]FIG. 8 is a view showing construction of a conventional cupproduct,

[0043]FIG. 9 is an illustration showing three-dimensional formingportions according to the conventional method, and

[0044]FIG. 10 is an illustration comparing three-dimensional shapes of aconventional cup and the cup of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] Preferred embodiments of the invention will be described nextwith reference to the accompanying drawings.

[0046] The present invention relates to a cup product for use in abrassier and a brassier using the cup product. The invention has somecharacterizing features also in the shape of a mold employed in theproduction of the cup product.

[0047] First, the structure of a planar lace fabric 1 to be manufacturedwill be described.

[0048] As shown in FIG. 1, a planar lace fabric 1 for forming athree-dimensional lace material relating to the invention includes anornamental lace portion 2, a scallop portion 3 continuously adjacent theornamental lace portion (portion adjacent the lace portion 2 in the weftdirection normal to the knitting direction W of the fabric) and awaste-fabric portion 4 on the opposite side to the ornamental laceportion 2 across the scallop portion 3.

[0049] In this embodiment, the ground network of this planar lace fabricis not the more ordinary 4-course network, but a diamond-network whichis well-balanced between the warp and course directions.

[0050] In the above, the ornamental lace portion 2 is a lace portionprovided with a predetermined ornamental pattern. Specifically, in thecase of a raschel lace for example, such lace portion may be produced byknitting onto the net, as its ground network, a number ofpattern-forming yarns 2 a according to a predetermined ornamentalpattern.

[0051] On the other hand, the scallop portion, or simply called“scallop”, is a portion formed continuous in the wave-like form alongthe knitting direction of the lace. Specifically, in the case of theraschel lace for example, this scallop portion is formed by knitting, onthe net, a plurality of scallop-forming yarns 3 a, a kind ofpattern-forming yarn, into predetermined loops R to form an ornamentalpattern, so that the number of loops R form the continuous wave-formalong the knitting direction of the lace. More particularly, a pluralityof waves are formed one after another along the knitting direction W, asshown.

[0052] The waste-fabric portion 4 is basically a simple network withoutany pattern-forming yarns, and this portion of the fabric may be readilycut.

[0053] In this respect, it should be noted, however, that there willoccur no inconvenience in the application of the present invention evenif any pattern-forming yarn may be present in this waste-fabric portionor not or which the structure of this waste-fabric portion is similar tothat of other ornamental pattern forming portion.

[0054] Further, as shown in FIG. 1, an end of the waste-fabric portion 4(on the extreme opposite side to the scallop portion 3) is constructedas a fabric-fixing portion 40, and this portion 40 uses thicker yarnsand has a more dense structure than the remaining portion 41 of thewaste-fabric portion, the remaining portion 41 being adjacent thescallop portion 3.

[0055] Moreover, a portion of the ornamental lace portion 2 in theimmediate vicinity of the scallop portion 3 is constructed as ascallop-reinforcing portion 20.

[0056] This scallop-reinforcing portion 20 too employs thicker yarnsthan the remaining ornamental lace portion 20 a. So that, this portion20 is provided with additional stiffness to effectively maintain theshape stability in the scallop portion 3. Specifically, while theremaining ornamental lace portion 20 a employs polyurethane yarns ofabout 210 denier, the scallop-reinforcing portion 20 employs yarns of420 denier, twice thickness.

[0057] Into the planar lace fabric 1 constructed as above, aswell-known, elastic yarns (not shown) are inserted along the wales ofthe fabric so as to provide elasticity in the warp direction of thefabric and further elastic yarns (not shown) are employed as weft yarns(i.e. the weft yarns forming the ground network) so as to provideelasticity also in the weft direction of the fabric. In this manner,this lace fabric 1 is provided with “two-way” elasticity.

[0058] The above describes the steps for forming the planar lace fabric1 as the preparatory steps for forming manufacturing thethree-dimensional lace material 5 of the invention.

[0059] These complete a material-knitting step.

[0060] Next, there will be described a three-dimensional forming step,an eliminating step for eliminating the waste-fabric portion and ajoining step for joining the fabric with an urethane cup Ca which ismolded separately from the fabric.

[0061] Three-dimensional Forming Step

[0062] In this three-dimensional forming step, the planar lace fabric 1obtained as above is formed (specifically, molded) into a predeterminedthree-dimensional shape. This three-dimensional step is carried out byusing a three-dimensional forming device 24 which includes a mold 23 formolding the fabric portion 22 and the fabric-fixing portion 21 to whichthe fabric portion 22 is to be fixed.

[0063] According to the method of this invention, referring to FIG. 3for example, the three-dimensional forming step is carried out withplacing the scallop portion 3 at an end of the three-dimensional shapeto be formed (i.e. in the case of FIG. 3, in order to align the end ofthe three-dimensional shape with the end of the cup Ca, an end or edgeof the cup Ca denoted with a solid line corresponds to the end of thethree-dimensional shape).

[0064] For this three-dimensional forming step, in fixing the planarlace fabric 1 to the three-dimensional forming device 24, thefabric-fixing portion 40 provided in the waste-fabric portion 4 isutilized. That is, as denoted with broken lines in FIG. 1, thisfabric-fixing portion 40 is utilized for the purpose of this fixing andalso the peripheral edge of the fabric across the scallop portion 3 isutilized for the fixing. And, the peripheral edge (the portion or areasurrounded by the solid line and the broken line in FIG. 1) of theornamental lace portion 4 on the opposite side to the scallop portion 3is also utilized for the fixing.

[0065] Further, as shown in FIG. 10(a), (c), a mold 23 of thethree-dimensional forming device includes a proximal cup portion 23 aclose to the center of the brassier corresponding to the valley betweenthe breasts and a distal cup portion 23 b distant from the center of thebrassier, the proximal cup portion 23 a having a greater bulgingcurvature than the distal cup portion 23 b and the proximal cup portion23 a having a maximum bulging center 23 c so that the brassier cupmolded by this mold may obtain a proximal cup portion 23 a, close to thecenter of the brassier corresponding to the valley between the breasts,having a greater bulging curvature than the distal cup portion distantfrom the center of the brassier, the proximal cup portion having amaximum bulging center.

[0066] Further, as shown in FIG. 10(d), which is a section taken alongan arrow in FIG. 10(c) (the upper portion of the cup), the bulgingcurvature is varied also in the vertical direction of the cup relativeto the lateral direction of the cup extending to and away from thecenter of the brassier, in such a manner that an upper up portion 23 ehas a greater bulging curvature than a lower cup portion 23 d.

[0067] With these arrangements, the mold is capable of forming theplanar lace fabric into a cup having a predetermined deformedthree-dimensional shape.

[0068] After the fixing of the planar lace fabric to thethree-dimensional forming device 24 described above, thethree-dimensional forming step of the fabric is effected by means of themold 23 and the formed three-dimensional shape is stabilized thereafter.

[0069] In the case of the present embodiment, nylon yarns 6-6 areemployed as the yarns forming the fabric. Therefore, the shapestabilizing step is completed by heat-setting the yarns.

[0070] Upon completion of the three-dimensional forming step above, thethree-dimensional lace material 5 obtained still is in a band-like shapehaving a plurality of partial projections M (projecting on the backside) as shown in FIG. 3. It is to be noted, however, this FIG. 3 showsa condition after the fabric has been joined with the urethane cup Ca.

[0071] Joining Step

[0072] In this step the three-dimensional lace material 5 having numberof partial projections M obtained as above is joined with separatelymolded polyurethane cups Ca, respectively.

[0073] This joining step is carried out generally by means of sewing.Instead, this step may be carried out by adhesive bonding, etc.

[0074] For this joining step, the scallop portion 3 of the lace materialis placed at the edge of the cup product C. With this, there may beobtained a three-dimensional lace product including the lining member Caand the three-dimensional lace material 5 joined together with thescallop portion 3 aligned with the end of the urethane cup Ca.

[0075] Eliminating Step

[0076] Next, the band-like three-dimensional lace material obtainedabove is subjected to an eliminating step for eliminating thewaste-fabric portion 4 along the scallop portion 3. Further, if each cupproduct is to be obtained independently, the peripheral edge of the cupis eliminated by cutting. The cutting line for this cutting is denotedwith a broken line in FIG. 3.

[0077] With these, there is obtained a cup product including thethree-dimensional ornamental lace portion 2 and the scallop portion 3 atthe end (in this case, it is noted that this cup product is a single cupcomprising the three-dimensional lace material and the urethane cup Cajoined together).

[0078]FIG. 4 shows the appearance of the cup product C obtained by themethod described above. Although this corresponds to the product shownin FIGS. 7 and 8, the product of FIG. 4 presents a smarter appearancedue to absence of tape at the upper end of the cup because the scallopportion S is provided integrally with the front-side cloth formed of thethree-dimensional lace material.

[0079] Finishing Step

[0080] Thereafter, by using the individual cup products obtained by theabove in an appropriate combination, the end product, e.g. a brassier,will be obtained. This step is effected by means of sewing.

OTHER EMBODIMENTS

[0081] (a) In the foregoing embodiment, the cutting/eliminating step iscarried out after the joining step of joining the band-likethree-dimensional lace material (with partial projections) with thepolyurethane cup Ca. Instead, it is also possible to cut the band-likethree-dimensional lace material into a predetermined shape and then joinit with each cup Ca. In this case, the assembly of eachthree-dimensionally formed lace fabric attached with the cup Ca willcorrespond to what is referred to herein as “a cup product for use in abrassier” and the each three-dimensionally formed lace fabric ormaterial per se will correspond to the “cup product for use in abrassier”.

[0082] (b) In the foregoing embodiment, the urethane cup Ca molded intoa predetermined shape is employed as the lining member. Instead, thislining member may be a non-woven fabric formed or molded into apredetermined shape.

[0083] (c) In the foregoing embodiment, the fabric-fixing portion 40 isprovided in the waste-fabric portion and the scallop-reinforcing portion20 is provided at a portion of the ornamental lace portion. However, itis not necessary for the invention to provide both of these portions.Such modified construction is shown in FIG. 5 corresponding to FIG. 1.

[0084] In the absence of these portions too, the three-dimensional lacematerial of the invention may be obtained by appropriately selecting thetypes, thickness, etc. of the lace forming yarns to be employed therein.

[0085] (d) In the foregoing embodiment, in the three-dimensional formingstep of the planar lace fabric, for producing the deformed cup, theplanar lace fabric is formed into a cup having its proximal portion anddistal portion differing from each other in the bulging curvaturesthereof, with the proximal portion having the maximum bulging center. Inaddition to the lace fabric described above, such deformed or irregularthree-dimensional forming process may be applied also to thepolyurethane cup, non-woven fabric, lining fabric, etc.

[0086] (e) In the foregoing embodiment, there was no description aboutthe specific type of the construction of the lace knitting machine forforming the lace material. This is because the method and material ofthe invention are applicable to any lace materials produced by any typeof lace knitting machines. Typical examples include the raschel laceproduced by the raschel knitting machine (including the falling-platetype, jacquard knitting machine), leaver lace produced by the leaverlace knitting machine, as well as embroidery lace produced by theembroidery lace knitting machine.

[0087] (f) In the foregoing embodiment, the method and material areapplied for manufacture of a brassier. However, these method andmaterial of the invention may be applied to any other garment articlessuch as a bra-slip, bra-camisole, body-suit, shorts, etc. Therefore,these products are generically referred to as “brassier products”herein.

[0088] (g) In the embodiment shown in FIG. 4, the entire cup forcovering the breast is formed of a single continuous lace fabric.Although this is the most preferred mode of embodying the presentinvention, other constructions are also possible. For instance, as shownin FIG. 6(a), another lace cloth or patch having a different ornamentalpattern may be joined by mans of sewing etc., to the lower cup portionso as to present the different ornamental patter from that of the uppercup portion. With such modified cup construction too, the intendedobject of the invention is achieved regarding the main body of the cupincluding the upper bulging center and its periphery.

[0089] Similarly, as shown in FIG. 6(b), the cup may be provided withdifferent ornamental laces between the right and left sides thereof.With this modified cup construction too, substantially samefunction/effect can be achieved with respect to the main body of thecup.

[0090] The present invention may be embodied in any other manner thandescribed above. The embodiments disclosed above are therefore not to betaken as limiting the invention, but only illustrating the invention. Itis understood that such modifications and variations will be apparent tothose skilled in the art without departing the scope of the inventionset forth in the appended claims.

What is claimed is:
 1. A cup product for use in a brassier, the cuphaving a cup for covering a breast, a scallop portion provided at aperipheral edge of the cup, and an ornamental lace portion provided overa surface of the cup; wherein the scallop portion and the ornamentallace portion comprise one continuous knitted lace fabric, and this lacefabric is formed into a three-dimensional shape by means of molding withthe scallop portion being placed at an end of the three-dimensionalshape.
 2. The cup product for use in a brassier according to claim 1,wherein the continuous knitted lace fabric is formed by means of themolding over the peripheral edge of the cup around a maximum bulgingcenter thereof.
 3. The cup product for use in a brassier according toclaim 1 or 2, wherein the knitted lace fabric is an elastic lace fabrichaving elasticity in either a weft direction or warp direction of thefabric or elasticity in both these directions.
 4. The cup product foruse in a brassier according to claim 1 or 2, wherein a proximal portionof the cup close to the center of the brassier corresponding to the“valley” between the breasts has a greater bulging curvature than adistal portion of the cup distant from the center of the brassier. 5.The cup product for use in a brassier according to claim 1 or 2, whereinthe maximum bulging center of the cup is located at the proximal cupportion adjacent the center of the brassier corresponding to the valleybetween the breasts.
 6. A brassier product using the cup productaccording to any one of claims 1-5.